Method for blending a gas into a high viscosity liquid

Abstract: A foamable composition, comprising a viscous liquid and a gas homogeneously dispersed in the liquid is described herein. The composition is prepared by blending a pressurized gas with the viscous liquid in a mixing chamber. The flow rate of the pressurized gas into the mixing chamber is controlled as a function of the flow rate (19) of at least one high-viscosity liquid into said chamber. Our apparatus for preparing our composition includes a means (4) for controlling the flow rate of the pressurized gas as a function of (1) either the difference in the feed pressures of said gas and said liquid, or (2) a predetermined ratio of the volumes of liquid and gas present in said mixing chamber.

Description: The present invention relates to a method for obtaining a homogeneous dispersion of a pressurized gas in a high-viscosity liquid composition. It also relates to an associated apparatus for the controlled blending of a pressurized gas with a high viscosity liquid in a mixing chamber equipped with separate inlets for these two ingredients. The gas is distributed throughout the resultant foamed mixture as bubbles with a uniformly small size and distribution that are consistent as a function of time. The viscous liquid is preferably a curable organosiloxane composition. The prior art of this invention is presented in a commonly assigned and earlier published application, EP-A1 0 604 926, dated July 6, 1994. FR-A-1,505,772 discloses a process and an apparatus for continuously transforming a latex into a foam. In that process, a first signal/impulse from a latex feeding pump is directed to a counter/controller which in turn sends a second signal to an electrically actuated valve in a compressed gas stream to feed the gas into a mixing chamber. In DE-A1-38,18,760, a process for maintaining a constant mixing ratio of a large primary stream and a relatively small secondary stream is disclosed. In the process, the volume of the primary stream is measured and indicated by a first signal, and the duration of the supply of the secondary stream is measured and indicated by a second signal. The actual values of the said signals are continuously measured and compared with each other. The supply of the secondary stream is discontinued when the signal of the secondary stream equals or exceeds the signal of the primary stream, and the supply of the secondary stream is resumed when the signal of the secondary stream reaches its upper limit value. During our investigation into the fabrication of homogeneous high-expansion-ratio foams, we have found that dispersing the small amount of inert gas which is blended into the viscous liquid is capable of yielding enhanced quality of the cell dispersion in the cured foam. Methods for mixing pressurized gases into high-viscosity liquids are known for the production of whipped cream and urethane foams. However, as shown in the data plots of the drawings, it is very difficult to obtain uniform gas-liquid mixtures when pressurized gases are blended into high-viscosity liquids. The present invention provided a method and an apparatus capable of producing uniform dispersions of a pressurized gas in a high-viscosity liquid. The internal structure of the dispersions are consistent over the entire gas injection cycle, which can be repeated at a predetermined rate. The present invention controls the flow rate of a pressurized gas as a function of the flow rate of at least one high viscosity liquid. The gas and the liquid(s) are simultaneously fed into a mixing chamber wherein these ingredients are blended in a predetermined volume ratio to form a foamable composition. The apparatus includes a means for controlling the flow rate of the pressurized gas as a function of either the difference in the feed pressures of said gas and said liquid(s) or said predetermined volume ratio. In one embodiment of the present method the flow of pressurized gas into the mixing chamber begins up to one second prior to introduction of said liquid into the chamber during each cycle of liquid flow. In all enbodiments of the present apparatus, the cycles of liquid and gas flow in the respective supply lines are coordinated with the release from the discharge nozzle of the apparatus which is positioned above substrates to be coated with the foamable composition. This invention introduces a method for preparing and dispensing a foamable commixing chamber to form a foamable composition which results in a foam upon being dispensed and depressurized, said method comprising blending a pressurized gas with a high-viscosity liquid in the mixing chamber portion of an apparatus comprising the said mixing chamber to which is connected the outlet of at least one liquid supply line for the said liquid, the outlet of a pressurized supply line for the introduction of the said gas into the said mixing chamber and an outlet nozzle for dispensing the said composition from the said mixing chamber, wherein the said pressurized supply line contains means for controlling the flow rate of the said pressurized gas in the said pressurized supply line to provide a predetermined ratio between the flow rates of the said pressurized gas and the said liquid, the said means comprising at least one control valve that is actuated by a first electrical signal generated by a control element, wherein the presence and duration of the said first signal is a function of a second electrical signal received by the said control element, the said second signal being a function of (a) the flow rate of the said liquid in the said liquid supply line and (b) a third electrical signal received by the said control element that is a function of a predetermined variable selected from the difference between the feed pressures of the said gas and the said liquid and the ratio between the volumes of the said liquid and the said gas to be combined in the said mixing chamber. An important feature of the present method is controlling the flow rate of a gas in a pressurized line supplying a mixing chamber by means of at least one valve that is actuated by an electrical signal generated by a control element. The presence and duration of this output signal from the control element is determined by at least two electrical input signals supplied to the control element. One of the input signals is generated by a flow meter located in a liquid supply line for the mixing chamber, and is a function of the flow rate in this line. The second signal is a function of one of two predetermined values. One value is the mixing ratio for the gas and liquid supplied to the mixing chamber. The second predetermined value is the difference between the pressures under which the gas and liquid(s) are supplied to the mixing chamber. In one embodiment of the present apparatus the control element receives a third input signal that is generated by a flow meter located in the pressurized gas supply line and which is a function of the flow rate in this line. Control of the pressurized gas flow in the present method enables uniform dispersal of the gas in the high-viscosity liquid in the mixing chamber to yield a dispersion that is consistent and uniform over the entire mixing period. This consistency is achieved by eliminating the initial surge of gas concentration in the mixture and by reducing the time lag in desired gas concentration after introducing the high-viscosity liquid into the mixing chamber. Additional improvements in the uniformity of the dispersion and reduction in the mixing chamber size can be achieved by installing a mixing device in the mixing chamber. The pressurized gas is then introduced while the high-viscosity liquid is stirred by mixing device, represented by 5 in Figures 1, 2, 3 and 4. The mixing device can be a kinematic one employing stirring blades as shown in the drawings or a static mixing device. Figures 1, 2 and 3 are schematic diagrams of three embodiments of an apparatus useful in implementing the present method. Figure 4 and 5 are schematic diagrams showing two alternative embodiments of the gas supply line for the embodiment shown in Figure 2. Figure 6 is a schematic diagram of a check valve located in the pressurized gas and liquid supply lines of the apparatus shown in Figure 1, 2, 3 and 4. Figures 7(A) and 7(B) are plots showing the flow rates of a high-viscosity liquid and a pressurized gas as a function of time during intermittent addition of the high viscosity liquid into a mixing chamber in using the apparatus shown in Figures 1 and 3. Figures 8(A), 8(B) and 8(C) are plots showing the flow rates of a high-viscosity liquid and a pressurized gas as a function of time during intermittent addition of the high viscosity liquid into a mixing chamber in using the apparatus shown in Figures 2,4 and 5. Figures 9(A), 9(B) and 9(C) are plots showing the flow rates of the high-viscosity liquid and pressurized gas as a function of time during continuous feed in accordance with prior art methods for injecting a pressurized gas into a viscous liquid. Figures 10(A) and 10(B) are plots showing the flow rates of the high-viscosity liquid pressurized gas as a function of time during intermittent feed in accordance with prior art methods for injecting a gas into a pressurized liquid. In the specific cases illustrated in Figure 9 of the accompanying drawings, plot A shows that when a pressurized gas is blended into at a relatively high flow rate q 1 with a high-viscosity liquid that is being supplied at flow rate Q, an overshoot phenomenon, referred to as a surge, occurs during which excess pressurized gas is blended in during the initial injection period. When, on the other hand, the pressurized gas is admixed at a lower flow rate q 2 , plot C in Figure 9 demonstrates that a surge again occurs, but this time in combination with a delay in mixing into the high-viscosity liquid after the start of gas injection. As a result of these "overshooting" or surge phenomena, the foam obtained during the initial period of pressurized gas injection exhibits a non-homogeneous cell distribution and a non-uniform expansion ratio. This has required that at least the initial foam output be discarded. The surges and delays shown in the plots of Figure 9 become critical problems when the high-viscosity liquid and pressurized gas are introduced intermittently, as would occur during production of foam articles on a batch rather than a continuous basis. In the case of intermittent feed of the high-viscosity liquid as shown in plot A of Figure 10, cycling between a feed period T1 and an off period T2, the synchronous injection and mixing of the pressurized gas exhibits, as shown in plot B of Figure 10, that the gas flow rate as a function of time has a substantial surge following a time lag T3 after the start of the high-viscosity liquid feed. These phenomena make it almost impossible to produce a uniform foam product. Figures 1 - 5 of the accompanying drawings are schematic views of five embodiments of a device suitable for implementing the present method for blending a gas into a high-viscosity liquid. The output portion of these devices applies a foam gasket (E) along the top edge of a dust cover (D) as a large number of these covers are conveyed to our devices one at a time as part of a continuous operation. Referring now to the features common to the embodiments shown in Figures 1, 2, 3 and 4, 1 refers to a mixing chamber, 2 refers to a storage tank containing a high-viscosity liquid comprising a base portion (A) of a two-part, curable high viscosity liquid composition, 3 refers to a storage tank containing the curing agent portion (B) of the same high-viscosity liquid composition, 4A , 4B , and the combination of 4C and 27C , refer to means for controlling the flow rate of the pressurized gas (C). The devices that constitutes these means vary, and will be discussed in detail in connection with the individual embodiments of the present apparatus. A discharge nozzle 22 is connected to the bottom of the mixing chamber 1 via a flexible hose 21 . A robot (not shown) moves the discharge nozzle 22 in a single pass along the perimeter of the top edge of the dust cover (D). A foam gasket (E) is formed by the extrusion through the nozzle and application of a bead of the curable, high-viscosity liquid composition formed within the mixing chamber 1 . The mixing and extrusion steps are repeated as each dust cover (D) is successively moved into position under the discharge nozzle. This operation requires repetitive and intermittent discharge of a stream of a curable, high-viscosity liquid composition from the mixing chamber 1 . A stirring device 5 driven by a motor 6 is installed in the mixing chamber 1 . Liquid transport pumps 7 and 8 are located at the bottom of the storage tanks identified as 2 and 3 , respectively. Liquid material from these tanks passes through liquid supply lines 9 and 10 and check valves 11 and 12 to the top of the mixing chamber 1 . Check valves 11 and 12 are arranged to permit introduction of high-viscosity liquids (A) and (B) into the mixing chamber 1 from supply lines 9 and 10 during discharge of the curable, high-viscosity liquid composition from discharge nozzle 22 and to also discontinue this supply when further release from the discharge nozzle is to be discontinued. A pressurized gas is supplied through supply line 13 and check valve 14 to a mixing chamber inlet located in the central region of the wall of the mixing chamber 1 . Figure 6 depicts a preferred structure for check valves 11 , 12 and 14 . In this structure, valve disk 23 is urged toward the closed position by means of a spring 24 located in the gas supply line 13 . The conical valve seat 23a widens prior to its intersection with the wall surface of the mixing chamber 1 . In the closed position, valve disk 23 rests on valve seat 23a . During operation of the check valve, the disk enters into and withdraws from the mixing chamber 1 as shown by the dot-and-dash line. This structure for the check valve avoids retention or stagnation within check valve 14 of the pressurized gas C supplied through pressurized gas supply line 13 . It therefore makes possible a uniform discharge of gas into the high-viscosity liquid in the mixing chamber 1 and also achieves a further improvement in dispersion of the pressurized gas. Embodiment A (Figure 1) The flow rate control means 4A located in the pressurized gas supply line 13 of embodiment A of the present apparatus contains a flowmeter 15A and a control valve 16A whose aperture is controlled by an electrical signal i generated by a first control element 17A . Control element 17A receives a signal q from a second control element 18A and a signal j from flowmeter 15A located in the gas supply line. The result of these two signals is an output signal i that controls the size of the aperture in control valve 16A , located in the gas supply line. The information supplied to the second control element 18A consists of a signal Q based on the flow rate of liquid base portion (A), which is supplied from flowmeter 19 located in the high-viscosity liquid supply line 9 , and a signal based on the predetermined mixing ratio r. Control element 18A is programmed to provide a target flow rate q for pressurized gas (C) as a function of the information received by this control element. Control element 17A generates a signal i which is based on both the target flow rate q and the flow rate signal j detected by flowmeter 15A . This signal i regulates the size of the aperture in control valve 16A to yield a target flow rate for the pressurized gas. A three-way switching valve 20A is located in the gas supply line between check valve 14 and control valve 16A . The purpose of valve 20A is to direct the flow of the pressurized gas in the supply line either into the mixing chamber 1 or into the atmosphere. The operation of valve 20A is synchronized with the operation of discharge nozzle 22 by means of a signal from control element 18A . when the discharge nozzle 22 is open, valve 20A directs the gas flow into the mixing chamber. When the discharge nozzle is closed, valve 20A directs the flow of gas into the atmosphere through relief valve 25A . Relief valve 25A is programmed to open when the pressure in the gas supply line exceeds the predetermined pressure under which gas is supplied to the supply line. More specifically, the three-way valve 20A is synchronized with the switching operations of the discharge nozzle 22 in such a manner that pressurized gas is fed into the mixing chamber 1 only during discharge from nozzle 22 of foamable composition onto the top edge of a dust cover D. In this embodiment of the present apparatus the three-way valve 20A also regulates the timing of injection of pressurized gas into the mixing chamber in such a manner that the start of injection precedes by 0.1 to 1 second the opening of discharge nozzle 22 , which is synchronized with introduction of the high-viscosity liquids (A) and (B) into the mixing chamber from the high-viscosity liquid supply lines 9 and 10 . In embodiment A, high-viscosity liquids (A) and (B), stored in tanks 2 and 3 respectively, are fed through check valves 11 and 12 into the mixing chamber in synchronization with the discharge of foamable composition from nozzle 22 . Introduction of the pressurized gas (C) is controlled as a function of the flow rate of the two liquids to achieve a predetermined mixing ratio. The gas flow is initiated by switching the three-way valve 20A to direct flow through supply line 13 at a point in time that precedes by 0.1 to 1 second the introduction of base portion (A) and curing agent portion (B) into the mixing chamber from their respective storage tanks. Creation of this 0.1 to 1 second delay between introduction of the gas and liquid(s) makes possible a uniform injection of the pressurized gas, as shown in plot B of Figure 7. It is evident from this plot that the flow rate of the pressurized gas does not initially exceed the desired value during intermittent feed of the high-viscosity liquid (feed period T1 and off period T2 shown in plot A of Figure 7. Irrespective of the particular apparatus used to regulate the flow of gas in the pressurized supply line 13 , the present method is particularly effective in providing a uniform dispersion of the gas in a high-viscosity liquid when the liquid has a viscosity of at least 1,000 centipoise (1 Pa.s), preferably from 3,000 to 500,000 centipoise (3 to 500 Pa.s). Under these conditions, an even more microscopically dispersed state can be obtained by regulating the flow rate of the pressurized gas in the supply line 13 to achieve a volume ratio of from 0.5 to 50 Ncm 3 of gas per 100 g of high viscosity liquid. These ratios are preferably obtained using gas flow rates of 0.02 to 20 Ncm 3 /minute. The gas volumes are measured at 0° C and a pressure of 1 bar or 1 atmosphere (760 mm of mercury), also referred to as "standard conditions" and represented by N. Gas volumes measured under these conditions are thus referred to in the present specification as "Ncm 3 ". The actual flow rate of the gas in the supply line is preferably from 0.02 to 20 Ncm 3 /minute. Embodiment B (Figures 2, 4 and 5) This embodiment of the present apparatus provides intermittent and pulsed injections of pressurized gas into the mixing chamber. The pressurized gas supply line 13 is connected, via check valve 14 , with the mixing chamber inlet through the wall in the mid-region of the mixing chamber 1 , and an injection rate controller assembly 4B comprising two electrically operated switching valves, 15B and 16B , and a gas storage tank 17B is located between the check valve and the source of the pressurized gas. Switching (on/off) valves 15B and 16B are installed on the intake side and discharge side, respectively, of the injection rate controller assembly 4B . and tank 17B is installed between switching valves 15B and 16B . In the modification of embodiment B shown in Figure 4 of the accompanying drawings, the fixed capacity gas storage tank 17B is replaced by a variable capacity tank 17B' The switching valves 15B and 16B alternately open and close at a specified frequency based on a signal from control element 18B , and the open/close status of each of these valves is always opposite that of the other valve. In specific terms, when switching valve 15B is open, switching valve 16B is closed and a constant volume of pressurized gas ( C ) becomes temporarily stored in the tank 17B . When switching valve 15B subsequently closes, switching valve 16B then opens and the pressurized gas C stored in the tank 17B is discharged. The execution of these operations at the specified frequency results in the intermittent and pulsed discharge of pressurized gas from switching valve 16B on the discharge side and thus in its injection as individual pulses through check valve 14 into the high-viscosity liquid composition in the mixing chamber 1 . The flow controller assembly containing switching valves 15B and 16B and tank 17B , may be a combination of separate components as exemplified in Figures 2 , 4 and 5 . Alternatively, an assembly based on a single three-way valve can be used. Flowmeter 19 installed in high-viscosity liquid supply line 9 sends a signal to control element 18B that indicates the flow rate Q of the base portion of the high-viscosity liquid stored in tank A. The predetermined mixing ratio r is also input to control element 18B . Control element 18B performs the following two functions: (a) based on the mixing ratio r , control element 18B determines the pressurized gas injection rate q in proportion to the flow rate Q ; and (b) control element 18B controls an alternating switching between valves 15B and 16B that produces a pulse cycle that will yield this injection rate q . As a result of the operation of flow control apparatus 4B , when a high-viscosity liquid is fed into the mixing chamber at a variable flow rate as indicated by Q 1 and Q 2 in Figure 8(A), the pressurized gas is fed into the mixing chamber as the intermittent series of pulses shown in Figure 8(B) corresponding to the individual intermittent flow cycles. More specifically, when the high-viscosity liquid has flow rate Q 1 , the pressurized gas is injected as groups of pulses defined by the injection interval T 3 and the interrupt interval T 4 . When the flow rate of the high-viscosity liquid falls from Q 1 to Q 2 , the injection interval of the pressurized gas pulse is shortened from T 3 to T 5 and the interrupt interval is lengthened from T 4 to T 6 . This instantaneous and pulsed injection of the pressurized gas into the high-viscosity liquid produced by the elements in control apparatus 4B avoids overshoot and prevents a time lag after the start of the high-viscosity liquid feed. In addition, a uniform dispersion is obtained as a result of making the injection rate of the pressurized gas proportional to the flow rate of the high-viscosity liquid. Figure 4 depicts a modification of embodiment B, referred to as B'. In this modification, a piston type of variable-capacity tank 17B' replaces the constant-capacity tank 17B installed between switching valves 15B and 16B in the apparatus depicted in Figure 2. The volume of this variable-capacity tank is varied in proportion to the flow rate Q of the high-viscosity liquid in the liquid supply line 9 , which is measured using flowmeter 19 . In embodiment B shown in Figure 2, the injection rate of the pressurized gas is adjusted by changing the pulse cycle generated by the alternating operation of switching valves 15B and 16B . In embodiment B' illustrated in Figure 4, the pulse cycle generated by the alternating switching at switching valves 15B and 16B is held constant, and the volume of the variable-capacity tank 17B' is varied by the control element 18B in proportion to the predetermined mixing ratio r' and as a function of the flow rate Q of the high-viscosity liquid in liquid supply line 9 . The principle of operation of this alternative embodiment is the same as the example in Figure 2 in terms of the provided, pulsed injection of the pressurized gas, but its injection pattern differs from that of the apparatus depicted in Figure 2. Thus, as shown in Figure 8(C), the flow rate during each pulse is varied from K 1 to K 2 in response to the change from Q 1 to Q 2 in the flow rate of the high-viscosity liquid that is being intermittently fed into mixing chamber 1 . This apparatus is also capable of uniformly dispersing the pressurized gas into the high-viscosity liquid in the mixing chamber. Figure 5 depicts a second alternative arrangement of devices in assembly 4B of embodiment B for controlling the flow of pressurized gas. The pressurized gas supply line 13 shown in Figure 2 is modified by inserting a pressure-control valve 25B between switching valves 15B and the source of pressurized gas (C) by installing a pressure gauge 26B in the high-viscosity liquid supply line 9 . The pressure gauge 26B detects the feed pressure P L of the high-viscosity liquid in the liquid supply line 9 . The feed pressure of the pressurized gas in supply line 13 is controlled by controlling the size of the aperture of pressure-control valve 25B as a function of the liquid feed pressure P L and in proportion to the predetermined mixing ratio r'' . Regulating the pressure in the gas supply line balances the pressurized gas injection rate with the pressure of the high-viscosity liquid and thereby produces uniform dispersions of gas and liquids using the pulsed injection technique shown in plot C of Figure 8. Embodiment C (Figure 3) This embodiment of the apparatus used in connection with the present method injects the pressurized gas into the mixing chamber 1 under a feed pressure P G higher than the high-viscosity liquid feed pressure P L while providing a substantially constant pressure difference, Δ p , between these two feed pressures. The value of Δ p is preferably within the range of from 0.1 to 5.0 kg/cm 2 . Because Δ p can be expressed as a function of the flow rate Q L of the high-viscosity liquid using the equation Δ p = a x Q L + b , wherein a and b are constants, it is evident that this pressure difference Δ p must therefore also change when the flow rate Q L of the high-viscosity liquid changes. In addition to check valve 11 and flow meter 19 present in embodiments A and B of the present apparatus, the liquid supply line 9 of embodiment C also contains a pressure gauge 25C and an electrically operated switching valve 20C . The pressurized gas supply line 13 of embodiment C is connected across check valve 14 to the wall of the mixing chamber 1 at the middle of this chamber. The pressurized gas supply line 13 contains a pressure control valve 4C , switching valve 27C , and pressure gauge 26C . Pressure gauge 25C located in the high-viscosity liquid supply line 9 measures the feed pressure P L of the high-viscosity liquid, while pressure gauge 26C in the pressurized gas supply line 13 measures the feed pressure P G of the pressurized gas. The operation of switching valve 27C is synchronized with the opening and closing of discharge nozzle 22 as follows: switching valve 27C is open and pressurized gas is fed into the mixing chamber 1 when the discharge nozzle 22 is open. Switching valve 27C is closed, shutting of the supply of pressurized gas to the mixing chamber, when discharge nozzle 22 is closed. High-viscosity liquid feed pump 7 , whose rotation rate is controlled by a signal from flowmeter 19 , governs the feed pressure P L of the high-viscosity liquid. Control element 18C receives the feed pressure P L signal for the high-viscosity liquid from the pressure gauge 25C and also receives the signal based on the predetermined pressure difference, Δ p . Based on these two signals, control element 18C transmits a throttle signal to pressure control valve 4C which has the effect of making the pressurized gas feed pressure P G exceed the high-viscosity liquid feed pressure P L by the predetermined constant pressure difference Δ p . The pressurized gas ( C ) is injected under this feed pressure P G across check valve 14 into the high-viscosity liquid in the mixing chamber 1 . Injection of the pressurized gas C under a pressure P G controlled as described above makes possible a uniform injection of the pressurized gas, as shown in Figure 7(B), in which the pressurized gas does not exhibit a time lag or significant overshoot relative to the intermittent feed of the high-viscosity liquid into the mixing chamber 1. The composition of the high-viscosity liquids referred to as (A) and (B) is not critical to the present invention. The present method is particularly effective when used to prepare foamable organosiloxane compositions that cure by a condensation reaction with the simultaneous evolution of gas, typically hydrogen, that functions as a blowing agent for the composition. The organosiloxane compositions preferably comprise the following ingredients: (A) a base portion comprising a curable polyorganosiloxane containing at least 2 silanol groups in each molecule, preferably a silanol-terminated polydiorganosiloxane, and a condensation-reaction catalyst selected from metals of the platinum group of the periodic table, compounds of these metals and organotin compounds; and (B) a curing agent portion comprising the same polyorganosiloxane present in the base portion and an organohydrogensiloxane containing at least 3 silicon-bonded hydrogen atoms in each molecule. This curable composition forms a foam by entrapping at least a portion of the hydrogen generated as a by-product of the curing reaction. Preferred base compositions (referred to herein as high-viscosity liquid A) used our method comprise a platinum compound as the curing catalyst and at least one silanol-terminated polydiorganosiloxane. The curing agent portion, referred to as high viscosity liquid B, comprises the same silanol-endblocked polydiorganosiloxane present in (A) and an organohydrogensiloxane containing at least three silicon-bonded hydrogen atoms in each molecule. The base and curing agent portions are typically combined in a volumetric ratio of around 1 : 1. Other foams that can be prepared using the present apparatus and method include flexible and rigid polyurethane foams. These foams are prepared from a base agent comprising diisocyanate or polyisocyanate and a curing agent comprising the mixture of polyol and water. Likewise, no specific restrictions apply to the nature of the pressurized gas supplied to the mixing chamber in the present method, so long as the gas will not react with the ingredients of the high-viscosity liquid. Suitable gases include air, nitrogen, helium, argon and carbon dioxide. Among these gases, air is particularly preferred for its ease of handling.

Claims: A method for preparing and dispensing a foamable composition by blending a pressurized gas with a liquid in a mixing chamber to form a foamable composition which results in a foam upon being dispensed and depressurized, said method comprising blending a pressurized gas (C) with a high-viscosity liquid (A) in the mixing chamber portion of an apparatus comprising said mixing chamber (1) to which is connected the outlet of at least one liquid supply line (9) for said liquid (A), the outlet of a pressurized supply line (13) for the introduction of said gas into said mixing chamber (1) and an outlet nozzle (22) for dispensing said composition from said mixing chamber (1), wherein said pressurized supply line (13) contains means (4) for controlling the flow rate of said pressurized gas (C) in said pressurized supply line (13) to provide a predetermined ratio between the flow rates of said pressurized gas (C) and said liquid (A), said means (4) comprising at least one control valve (16A; 15B and 16B; 4C and 27C) that is actuated by a first electrical signal generated by a control element (17,18), wherein the presence and duration of said first signal is a function of a second electrical signal received by said control element (17,18), said second signal being a function of (a) the flow rate of said liquid (A) in said liquid supply line (9) and (b) a third electrical signal received by said control element (17,18) that is a function of a predetermined variable selected from the difference between the feed pressures of said gas (C) and said liquid (A) and the ratio between the volumes of said liquid (A) and said gas (C) to be combined in said mixing chamber (1). A method according to claim 1 wherein a) the flow rate of said gas (C) in said gas supply line (13) is controlled as a function of the flow rate of the high-viscosity liquid (A) in said liquid supply line (9) to obtain a predetermined volume ratio for said gas relative to said liquid, and b) the starting time for introduction of said gas into said mixing chamber (1) is adjusted to precede by 0.1 to one second the starting time for the introduction of said liquid into said mixing chamber. A method according to Claim 1 wherein the high-viscosity liquid (A) and pressurized gas (C) are intermittently introduced into said mixing chamber in a mutually synchronized manner. A method according to Claim 2 wherein said gas (C) is continuously supplied into the pressurized gas supply line and passes through a switching valve (20) that selectively alternates the flow path of said gas between said mixing chamber (1) and the atmosphere adjacent to the outside of said chamber, wherein said switching valve is installed between said flow rate controller 17 and the point of connection of said pressurized gas supply line to said mixing chamber, and wherein said switching valve directs said gas into said mixing chamber when said high-viscosity liquid (A) is being fed into said mixing chamber and directs said gas into the atmosphere outside of said chamber when the supply of said liquid into said mixing chamber is discontinued. A method according to claim 4 wherein a relief valve (25) is located in the flow path from said switching valve (20) to the atmosphere and said relief valve (25) is adjusted to open when the pressure of said pressurized gas (C) exceeds the injection pressure of the high-viscosity liquid (A). A method according to claim 1 wherein the viscosity of the high-viscosity liquid (A) is at least 1,000 centipoise (1 Pa.s) and the mixing ratio of said pressurized gas relative to said liquid is from 0.5 to 50 cm 3 of said gas, measured at standard temperature (0°C) and standard pressure (1 bar), per 100 g of said high-viscosity liquid. A method according to claim 1 wherein a stirring means (5) is located in said mixing chamber (1) and the pressurized gas (C) is injected into the high-viscosity liquid (A) while said liquid is being stirred by said stirring means. A method according to claim 1 wherein the high-viscosity liquid (A) is a foamable organosiloxane composition that cures by the reaction of silicon-bonded hydrogen atoms with silicon-bonded hydroxyl groups.

Inventors: ISHIDA KOICHI, NAKAGAWA TERUXUKI, WATANABE TAKEHIRO, ISHIDA, KOICHI, NAKAGAWA, TERUXUKI, WATANABE, TAKEHIRO, ISHIDA, KOICHI, MAIN OFFICE FOR RESEARCH AND DEV., NAKAGAWA, TERUXUKI, MAIN OFFICE FOR RES. AND DEV., WATANABE, TAKEHIRO, MAIN OFFICE FOR RES. AND DEV.
Applicants: DOW CORNING TORAY SILICONE, DOW CORNING TORAY SILICONE CO., LTD.
Application year: 1994
Main classification: B01F15
IPC codes: B01F3, B01F15